NOTE: This procedure alleviates the need for the “H” bar to hold down liners during projection measurements.
Liner projection components
2. Hard washer.
4. Fabric washer.
5. Spacer plate.
6. Spacer plate gasket.
7. Cylinder liner.
Install clean liners or cylinder packs (without the filler band or the rubber seals), spacer plate gasket and clean spacer plate.
Install bolts and washers, as indicated previously, in the holes indicated with an X. Install all bolts or the six bolts around the liner. Tighten the bolts to a torque of 95 N·m (70 lb ft).
Use the 8T0455 Liner Projection Tool Group to measure liner projection at positions indicated with and A, B, C and D. Record measurements for each cylinder. Add the four readings for each cylinder and divide by four to find the average.
If the liner projections are out of specification, try rotating the liner or install the liner in another bore to see if the measurements improve.
Do not exceed the maximum liner projection of 0.175 mm (0.0069 in). Excessive liner projection will contribute to liner flange cracking.
With the proper liner projection, mark the liners in the proper position and set them aside.
When the engine is ready for final assembly, the o-ring seals, cylinder block and upper filler band must be lubricated before installation.
If the lower o-rings are black in color, apply liquid soap on the lower o-ring seals and the cylinder block. Use clean engine oil on the upper filler band.
If the lower o-rings are brown in color, apply engine oil on the lower o-ring seals, the cylinder block and the upper filler band.
NOTE: Apply liquid soap and/or clean engine oil immediately before assembly. If applied too early, the filler bands may swell and be pinched under the liners during installation.